Innovative Metal Forming Processes

National Machinery LLC's dedicated engineering division, Met-MAX Innovations, has the total objective of developing innovative metal forming processes. Its most recent technological success has led to three new patents for net forming bearing rollers.

The overall technology yields a more complete and stronger part, while also being more cost effective, says National Machinery.
This new method for cold forming near net shape metal roller blanks for anti-friction bearings, demonstrates a significant
manufacturing improvement over the pre-existing method.

Traditionally cold formed rollers are formed in a single die where "body sized" wire is cut off and the material is forced to flow
into the radii of the tool and die cavity. This can imbed cut-off imperfections into the roller's critical end radii. In order to generate the force needed to fill the corners, the material spills out between the tool and die. This creates a flash band, and it is common that the radii will still not fill uniformly. Extensive grinding is then needed to remove imperfections and finish the end radii adding significantly to the cost of the finished roller. These secondary operations are necessary because of the limitations of the traditional roller bearing forming methods and tooling used.

National's patents for cold formed roller blanks can greatly reduce grinding costs and result in an improved metal grain structure. The enhanced cold-formed part is produced from tooling that accurately forms the part without flash, and with a continuous grain structure that follows the contours of the end radii, thereby avoiding irregularities in the finished product. The improved grain structure prevents premature bearing failure and extends service Life of the roller. This process requires a specialized progressive FORMAX Plus· machine. These machine enhancements can be incorporated on any size of new FORMAX Plus cold former. With Nationals patented roller bearing forming process, you will achieve stronger, higher quality rollers while reducing expensive secondary procedures.

The technology behind these patents can be applied to other applications that require extreme symmetry and TIR requirements. including solid/hollow parts. Improved forming methodology for bearing rollers is just one example of the valuable technology National Machinery LLC can apply to your parts forming needs. The experts at National are ready to help you find better forming solutions for all your challenging parts.

Fastener + Fixing Magazine - Issue 68 March 2011